An Underdrain for a Filter System for Filtering Water or Wastewater and a Method of Washing a Filter System

ABSTRACT

An apparatus for use in a filter system for filtering water or wastewater. The apparatus preferably includes at least one underdrain lateral having at least an inner chamber, a first outer chamber and a second outer chamber. The first outer chamber and the second outer chamber are preferably in fluid communication with the inner chamber. The inner chamber, the first outer chamber and the second outer chamber are preferably formed by an inner liner and an outer liner. The outer liner is a separate piece from the inner liner and surrounds the inner liner. The inner chamber is preferably configured to simultaneously receive a liquid and a gas during a washing procedure including simultaneous use of a liquid and gas to clean a filter bed to create a liquid and gas interface in the inner chamber.

RELATED APPLICATIONS

The subject patent application is a continuation-in-part of U.S. patentapplication Ser. No. 13/506,852 filed on May 21, 2012. The entirecontent of U.S. patent application Ser. No. 13/506,852 is incorporatedherein by reference.

FIELD OF THE INVENTION

The present invention is directed to water and/or wastewater filtersystems for filtering impurities from a liquid. More particularly, thepresent invention is directed to an underdrain for a filter system and amethod of washing a filter system using the underdrain.

BACKGROUND OF THE INVENTION

Various filter systems have been developed to filter water andwastewater. Typical filter systems include but are not limited to upflowfilters, upflow clarifiers, a downflow downflow clarifiers, bi-flowfilters as well as various combinations of the aforementioned filtersystems. The terms upflow filter and upflow clarifier refer to filtersystems in which influent to be filtered is directed in an upward pathto remove impurities. Conversely, the terms downflow filter and downflowclarifier refer to filter systems in which the influent is directed in adownward path to remove impurities. Bi-flow filters refer to filtersystems in which the influent is directed in both a downward path and anupward path to remove impurities. The upflow fitters/clarifiers,downflow filters/clarifiers and bi-flow filters include one or morefilter beds formed from one or more layers of filter media. The filtermedia may be supported by one or more layers of gavel. Alternatively,the one or more gravel layers may be replaced with a porous plate orother direct retention systems.

In a combined system, for example, an upflow fitter/clarifier followedby a downflow filter, the influent is initially directed upwardlythrough the upflow filter/clarifier to remove a predetermined percentageof the impurities in the influent and then directed downwardly throughthe downflow filter to remove the remaining impurities to within anacceptable limit. Where the filter system includes multiple downflowfilters connected in series, the influent is directed downwardly througheach of the downflow filters one after the other to remove impuritieswithin an acceptable limit.

Regardless of the type of granular bed filter system and/or the type ofthe liquid to be filtered, it is common for the filter system to includean underdrain. The underdrain directs and receives fluids duringoperation of various cycles of the filter system including thefiltration cycle (also referred to as a service run) and a washingcycle. The washing cycle may be performed by directing the washing fluidin a path opposite to the path of influent during the filtration cycleor the washing cycle may be performed by directing the washing fluid inthe same path as the path of the influent during the filtration cycle.The washing fluids may include influent, pre-filtered water, air orother suitable gas. A key function of the underdrain is to evenlydistribute the washing fluid through the filter bed during the washingcycle so that at least a significant amount of the impurities trapped inthe filter can be removed. In the event that the underdrain does notevenly distribute the washing fluid through the filter bed, the filterbed will likely not be properly cleaned. At a minimum, this will causemuch shorter filtration cycles and more washing cycles. This isundesirable, as the filter system typically cannot operate in thefiltration cycle during a washing cycle.

There are many different types of underdrain systems currently marketedfor use in water filtration. Some underdrains are used for water onlybackwash and some are capable of introducing air only, water only, orsimultaneous liquid and air.

A common type of underdrain is the “lateral” style. This type ofunderdrain is typically made of injection molded or extruded plastic orextruded clay. The underdrain blocks are arranged in rows termed“laterals”. The laterals are typically spaced on approximately 12 inchcenters leaving an approximately 1 inch space between the laterals.There are two common types of combined air/water lateral typeunderdrains. One type is configured to introduce air and water into acenter compartment that directs the air and water through separateinternal orifices into two adjacent, outer compartments. The air andwater escape only from the two adjacent, outer compartments into thefilter bed from combined air/water orifices in the two adjacent, outercompartments. The two adjacent, outer compartments form in essence dualinternal laterals that extend generally the length of the singlelateral. This type of system is subject to mal-distribution of one ormore of the washing fluids. Specifically, the washing fluid can exit theouter compartments in an uneven manner along the length of theunderdrain lateral leading to partial cleaning of the filter media.Underdrain laterals are subject to uplift forces that tend to separatethe underdrain laterals from the filter floor. A common source of thisuplift force is due to the upward flow of water and/or air pushingagainst the filter floor with a force equal and opposite to theresistance of the flow across the underdrain lateral. Should theunderdrain laterals become sufficiently separated from the filter floor,the filter will become inoperable. All of the media must be removed andthe underdrain repaired or completely removed. This is obviouslyextremely undesirable. Therefore, one aspect of a preferred embodimentof the present invention is to provide a cost effective manner ofanchoring the underdrain laterals to the filter floor.

OBJECTS AND SUMMARY OF THE INVENTION

An object of the present invention is to provide a novel and unobviousunderdrain and a method of washing a filter system using the novel andunobvious underdrain.

Another object of a preferred embodiment of the present invention is toprovide a lateral type underdrain that ensures uniform distribution ofwashing liquid.

A further object of a preferred embodiment of the present invention isto provide an underdrain lateral that ensures uniform distribution of awashing gas.

Yet another object of a preferred embodiment of the present invention isto provide fluid pressure tap member that can be readily connected to aportion of the underdrain lateral to monitor fluid pressure of washingfluid to ascertain if the washing fluid is being uniformly distributedby the underdrain lateral.

Still another object of a preferred embodiment of the present inventionis to provide a support assembly that prevents relative movement betweenan inner liner and an outer liner of an underdrain lateral.

Yet still another object of a preferred embodiment of the presentinvention is to provide a mal-distribution member for an underdrainlateral that forms at least a portion of a fluid receiving sub-chamber.

It must be understood that no one embodiment of the present inventionneed include all of the aforementioned objects of the present invention.Rather, a given embodiment may include one or none of the aforementionedobjects. Accordingly, these objects are not to be used to limit thescope of the claims of the present invention.

In summary, one preferred embodiment of the present invention isdirected to an apparatus for use in a filter system for filtering wateror wastewater. The apparatus includes at least one underdrain lateralblock having a first outer sidewall, a second outer sidewall and atleast one inner wall forming at least an inner chamber, a first outerchamber and a second outer chamber. The first outer chamber and thesecond outer chamber are in fluid communication with the inner chamber.A first mal-distribution member is disposed in the first outer chamberfor preventing mal-distribution of a washing fluid. A secondmal-distribution member is disposed in the second outer chamber forpreventing mal-distribution of a washing fluid. The first outer chamberand the second outer chamber each have a first space for receiving awashing fluid. The first outer sidewall has at least one openingadjacent the first space of the first outer chamber through which awashing liquid in the first space of the first outer chamber can exitthe at least one underdrain lateral through the first outer sidewall.The second outer sidewall has at least one opening adjacent the firstspace of the second outer chamber through which a washing fluid in thefirst space of the second outer chamber can exit the at least oneunderdrain lateral through the second outer sidewall. The first space ofthe first outer chamber is disposed above or below the firstmal-distribution member and the first space of the second outer chamberis disposed above or below the second mal-distribution member.

Another preferred embodiment of the present invention is directed to anapparatus for use in a filter system for filtering water or wastewater.The apparatus includes an underdrain lateral block having a first outersidewall, a second outer sidewall and at least one inner wall forming atleast one primary chamber, at least one tower secondary chamber, atleast one intermediate secondary chamber and at least one uppersecondary chamber. The intermediate secondary chamber is disposedbetween the at least one tower secondary chamber and the at least oneupper secondary chamber. The primary chamber is in fluid communicationwith the at least one intermediate secondary chamber. The at least oneintermediate secondary chamber is in fluid communication with the atleast one lower secondary chamber and the at least one upper secondarychamber such that the at least one intermediate secondary chamberdirects a washing fluid to the at least one lower secondary chamber andthe at least one upper secondary chamber wherein the primary chamberreceives a washing fluid prior to the at least one lower secondarychamber, the at least one intermediate secondary chamber and the atleast one upper secondary chamber.

A further preferred embodiment of the present invention is directed toan apparatus for use in a filter system for filtering water orwastewater. The apparatus includes at least one underdrain lateral blockhaving an inner liner and an outer liner firming an inner chamber, afirst outer chamber and a second outer chamber. The first outer chamberand the second outer chamber are in fluid communication with the innerchamber. The outer liner surrounds at least a portion of the innerliner. A support assembly is provided for preventing relative movementbetween the inner liner and the outer liner when a washing fluid isdirected through the at least one underdrain block. The support assemblyincludes a first member engaging a portion of the inner liner and asecond member engaging a portion of the outer liner.

Still a further preferred embodiment of the present is directed to anapparatus for use in a filter system for filtering water or wastewater.The apparatus includes at least one underdrain lateral having at leastone outer wall and at least one inner wall forming at least a firstchamber and a second chamber. The first chamber is in fluidcommunication with the second chamber. The underdrain lateral furtherincludes a sub-chamber for receiving and directing a washing fluid. Thesub-chamber is formed in the first chamber. A first mal-distributionmember is disposed in the first chamber for preventing mal-distributionof a washing fluid. The first mal-distribution member and at least aportion of the at least one inner wall form at least a portion of thesub-chamber wherein the mal-distribution member is a separate piece fromthe at least one inner wall.

Still another preferred embodiment of the present invention is directedto an apparatus fir use in a filter system for filtering water orwastewater. The apparatus includes at least one at least one underdrainlateral having at least one outer wall and at least one inner wallforming at least a primary chamber and a secondary chamber. The primarychamber is in fluid communication with the secondary chamber such thatthe primary chamber directs a washing fluid during a washing cycle intothe secondary chamber. The apparatus further includes a fluid pressuretap member connected to the at least one underdrain lateral such thatthe fluid pressure tap member is operably associated with a fluiddischarge opening formed in the at least one underdrain lateral. Thefluid pressure tap member includes a tap configured so that at least onecomponent of a pressure monitor can be connected to the tap so thatpressure of a fluid passing through the fluid discharge opening can bemonitored.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view of a filter (with filter mediaremoved) with underdrain laterals formed in accordance with a preferredembodiment of the present invention.

FIG. 2 is a cross-sectional view of an underdrain lateral formed inaccordance with the preferred embodiment illustrated in FIG. 1.

FIG. 3 is a perspective view of an outer liner of the preferredunderdrain lateral illustrated in FIG. 1.

FIG. 4 is a perspective view of an inner liner of the preferredunderdrain lateral illustrated in FIG. 1.

FIG. 5 is another perspective view of an inner liner of the preferredunderdrain lateral illustrated FIG. 1.

FIG. 6 is an exploded view of the embodiment illustrated in FIG. 1.

FIG. 7 through 11 are views of various aspects of the preferred anchorassembly.

FIGS. 12 and 13 illustrate an alternative means to supply a washingfluid to the preferred underdrain laterals.

FIG. 14 is another alternative end cap for the preferred underdrainlaterals.

FIG. 15 is a further alternative end cap for the preferred underdrainlaterals.

FIG. 16 is an elevation view of an alternative form of anchor assembly.

FIG. 17 is a cross-sectional view of a preferred underdrain lateral withthe alternative form of anchor assembly illustrated in FIG. 16.

FIG. 18 is a cross-sectional view of a preferred form of misalignmentprevention collar.

FIG. 19 is an enlarged cross-sectional view of the portion of FIG. 18within the dashed lines.

FIG. 20 is a perspective view of an underdrain lateral block and supportassembly formed in accordance with another preferred embodiment of thepresent invention as seen from the side.

FIG. 21 is a perspective view of the underdrain lateral block andsupport assembly illustrated in FIG. 20 as seen from a different vantagepoint.

FIG. 22 is a perspective view of the underdrain lateral block andsupport assembly illustrated in FIG. 20 as seen from a different vantagepoint.

FIG. 23 is a fragmentary perspective view of a filter housing havingthree underdrain laterals formed from the underdrain block illustratedin FIG. 20.

FIG. 24 is an enlarged view of FIG. 23 showing in greater detail thesupport assembly illustrated in FIG. 20.

FIG. 25 is a plan view of the inner liner in blank form (i.e., prior tobending) of the underdrain lateral block illustrated in FIG. 20.

FIG. 26 is a perspective view of the inner liner of the underdrainlateral block illustrated in FIG. 20.

FIG. 27 is a cross-sectional view of the inner liner of the underdrainlateral block illustrated in FIG. 20.

FIG. 28 is a cross-sectional view of the upper portion of the innerliner of the underdrain lateral block illustrated in FIG. 20.

FIG. 29 is a plan view of the mal-distribution member in blank form(i.e., prior to bending) of the underdrain lateral block illustrated inFIG. 20.

FIG. 30 is a side view of the mal-distribution member of FIG. 29.

FIGS. 31A THROUGH 31E illustrate several of many possible differentconfigurations for the mal-distribution member illustrated in FIGS. 29and 30.

FIG. 32 is a plan view of the outer liner in blank form (i.e., prior tobending) of the underdrain lateral block illustrated in FIG. 20.

FIG. 33 is a side view of one preferred form of underdrain lateral.

FIG. 34 is a perspective view of the underdrain lateral illustrated inFIG. 33.

FIG. 35 is an enlarged fragmentary perspective view of one end of theunderdrain lateral illustrated in FIG. 33.

FIG. 36 is an end view of the underdrain lateral illustrated in FIG. 33.

FIG. 37 is a fragmentary cross-sectional view the underdrain lateralillustrated in FIG. 33.

FIG. 38 is a perspective view of the pressure tap member connected tothe mal-distribution member and inner liner.

FIG. 39 is a perspective view of the body of the pressure tap member.

FIG. 40 is a perspective view of the body of the pressure tap membertaken from a different vantage point than FIG. 39.

FIG. 41 is a perspective view of the body of the pressure tap membertaken from a different vantage point than FIG. 39.

FIG. 42 is a perspective view of another form of pressure tap member.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

The preferred forms of the invention will now be described withreference to FIGS. 1-42. The appended claims are not limited to thepreferred forms and no term and/or phrase used herein is to be given ameaning other than its ordinary meaning unless it is expressly statedthat the term and/or phrase shall have a special meaning. The termfilter as used herein is broadly interpreted to include a device inwhich at least a portion of the impurities in a liquid are removedincluding but not limited to a clarifier, a polishing filter and/or acontactor.

FIGS. 1-41

Referring to FIG. 1, a portion of filter A having a floor 2 and fourfilter walls 4 (only two of which are shown) includes a plurality ofunderdrain laterals B formed in accordance with a preferred embodimentof the present invention. The filter media has been removed so that theunderdrain laterals can be readily seen. It is to be noted that FIG. 1depicts one of numerous possible configurations of the presentinvention. It should be noted that the filter A can be formed from anysuitable material including but not limited to concrete and stainlesssteel or other metal. Further, filter A can take any shape as desiredincluding but not limited to square, rectangular and circular. Thenumber of underdrain laterals B that are used in any given underdrainsystem will depend on the size of the filter.

Preferably, each of the underdrain laterals B are formed from aplurality of blocks C placed end to end with the joints between adjacentblocks C sealed by any suitable sealing method. However, underdrainlaterals B may be formed from one long underdrain block C. Theunderdrain blocks C, in the most preferred embodiment, are formed fromstainless steel. However, any suitable material may be used. Preferably,each of the underdrain blocks C are formed in a similar manner and,therefore, only one underdrain block C will be described in detail.

Referring to FIGS. 1 to 11, the preferred form of underdrain block Cwill now be described. The first of the two main components ofunderdrain block C is an inner liner 6 seen in for example FIGS. 4 and5. Preferably, the inner line 6 is formed from a single piece ofstainless steel. Apex 8 of liner 6 includes to vertically extendingportions that mate flush to each other. The apex 8 can be sealed in anyknown manner including resistance welding. The base 10 of the liner 6includes a plurality of openings (not shown) along the length of theliner 6 to receive a washing liquid from center flume D. It should benoted that the present invention is not limited to use with center typeflumes but can be used in any filter system including filter systemsthat do not have a flume. The openings in base 10 preferably receive agas conduit 12 (see FIG. 2) so that the inner liner 6 can receive awashing gas including but not limited to air from flume R As readilyevident from the above discussion, chamber 14 formed by the inner liner6 simultaneously receives a liquid and a gas during a backwash usingsimultaneous liquid and gas. It should be noted, that the presentinvention is not limited to filter systems employing a simultaneousliquid and gas washing procedure. Rather, the present invention can beused in filter systems employing any of the following washingprocedures: (i) a separate liquid and gas washing procedure; (ii) aliquid only washing procedure; (iii) a gas only washing procedure; (iv)and a washing procedure that employs simultaneous liquid and gas for atleast a portion of the washing procedure.

A liquid mal-distribution member 16 is formed in each inclined sidewall18 of liner 6. Preferably, members 16 are positioned below thegas/liquid interface formed in chamber 14 when a simultaneous liquid andgas washing procedure is employed. In the most preferred embodiment,each liquid mal-distribution member 16 is formed by folding anappropriate portion of the single piece of stainless steel so that eachliquid mal-distribution member has two abutting segments of stainlesssteel, an upper segment 20 and a lower segment 22, with a plurality ofopenings 24 or slots formed in each of the abutting segments ofstainless steel. Preferably, each opening in the ripper segment 20 isaligned with an opening formed in the lower segment 22. As explained inmore detail below, this arrangement of openings in liquidmal-distribution members 16, will allow a washing liquid to pass throughthe mal-distribution members 16 after exiting chamber 14 throughopenings 26 formed in the lower portions of sidewalls 18 of liner 6. Thenumber, shape and spacing between openings 26 may be varied as desired.Moreover, the openings 26 may be knock-outs with only a portion of theknock-out connected to the corresponding sidewall 18 while otherportions of the knock-out are detached from the corresponding sidewall18 creating an opening for fluid to pass through. The knock-outs can beinwardly or outwardly extending with respect to chamber 14, i.e., theknock-outs could extend outwardly from chamber 14 or could extend intochamber 14.

A plurality of gas mal-distribution members 30 are formed in eachinclined sidewall 18 of liner 6. Preferably, members 30 are outwardlyextending protrusions formed in the single piece of stainless steelforming liner 6. Preferably, members 30 are positioned above the asliquid interface formed in chamber 14 when a simultaneous liquid and gaswashing procedure is employed. A plurality of openings 32 are formedaround members 30 for allowing a washing gas to exit chamber 14 when awashing gas is use in the washing procedure. The number, size and shapeof openings 32 may be vary as desired.

The second rain component of blocks C is outer liner 40 as seen in forexample, FIGS. 1, 2, 3 and 6. Liner 40 is preferably formed from asingle piece of stainless steel. Apex 42 of liner 40 includes tovertically extending portions that mate flush to each other. The apex 42can be sealed in any known manner including resistance welding. The base44 of the liner 40 includes a plurality of openings (not shown) alongthe length of the liner 40. Each of the openings in base 44 is alignedwith a corresponding opening in base 10 of liner 6 to allow a washingliquid to flow from the flume D into chamber 14 of liner 6. The openingsin base 44 preferably receive a gas conduit 12 (see FIG. 2) so that theinner liner 6 can receive a washing gas including but not limited to airfrom flume D. Each inwardly inclined sidewall 46 of liner 40 includes aplurality of inwardly extending protrusions 48. Preferably, eachinwardly extending protrusion 48 is aligned with and abuts acorresponding outwardly extending protrusion 30 formed in the sidewalk18 of liner 6.

As seen in FIG. 2, outer liner 40 surrounds inner liner 6 forming twoouter chambers 50 and 52 on opposite sides of chamber 14. Chamber 50 cancommunicate but is not required to communicate with chamber 52 at theapex of the underdrain block C. However, as shown in FIG. 2, chamber 50does not communicate with chamber 52 at the apex as will 53 formed byapex 8 of liner 6 separates the two outer chambers 50 and 52. However,openings can be readily formed in wall 53 to permit communicationbetween chamber 50 and chamber 52. Each of the chambers 50 and 52 havean upper compartment 54 formed above member 16 and a lower compartment56 formed below member 16. Each of the lower compartments 56 receives awashing liquid from inner chamber 14 through openings 26 during awashing procedure including a washing liquid.

Openings may be formed in sidewalls 46 of outer liner 40 below members16 to allow some liquid in lower compartments 56 to directly enter thefilter bed. The filter bed may include one or more layers of filtermedia supported by one or more layers of gravel. The bulk of the washingliquid in lower compartments 56 will travel through the openings 24 inthe corresponding distribution member 16 and enter the correspondingupper compartment 54. The washing liquid exits upper compartment 54through a plurality of openings or slots 60. Forcing the bulk of thewashing liquid entering lower compartment 56 through members 16 beforeexiting block C, directly results in a significant reduction ofmal-distribution of the washing liquid.

When a washing liquid and washing gas are simultaneously used to wash afilter bed, a gas/liquid interface will be formed in chamber 14 abovemembers 16. The gas will exit chamber 14 through the openings 32 formedin sidewalls 18 above members 16 into upper compartments 54. Aliquid/gas interface will in turn be formed in each of the uppercompartments 54. The washing gas will exit compartments 54 above thecorresponding gas/liquid interface and pass into the filter bed.However, prior to exiting upper compartments 54, the washing gas travelsaround the mating protrusions 30 and 48 and upwardly through thechannels formed between adjacent pairs of mating protrusions 30 and 48.In this manner, mal-distribution of the washing gas is greatly reduced.

Referring to FIGS. 2 and 6 to 11, one preferred manner of anchoringunderdrain blocks C will now be described. Referring to FIGS. 6 and 8, aflume distribution plate 70 having a plurality of fluid guides orcollars 72 extend upwardly from the flume distribution plate. Each fluidguide or collar 72 is associated with one underdrain lateral as shown inFIGS. 2 and 7. While these figures depict the guide or collar 72disposed outside of the corresponding block C, it should be noted thatcollar 72 can extend in the corresponding underdrain block. In the caseof an existing flume, the flume distribution plate 70 can be fixed tosidewalk 74 and 76 of flume D by angle brackets 79 and bolts illustratedin FIG. 8. However, it should be readily appreciated that numerous otherfastening arrangements may be used. Grout 78 is preferably poured aroundthe collars 72 to provide a tight seal between the flume and plate 70. Asealing plate 80 (FIG. 6) is placed over plate 70 as shown in FIG. 6.Sealing plate 80 has a plurality of openings 82 that align with collars72. Preferably, sealing plate 80 is not fixed to plate 70. Sealing plate80 enhances the seal around flume D. In new installations, where thefilter housing is formed from concrete, plate 70 may be embeddeddirectly in the floor of the filter adjacent or in the flume.

The anchor assembly of the present invention uses each of the collars 72to create a lower anchor point in the flume to secure each underdrainlateral B to the floor 2 of the filter. Referring to FIGS. 2 and 6 to11, the preferred anchor assembly includes a top support plate 90 thatmates with the upper portion of block C and a pair of lower supportclips 92 that engage an inner surface of collars 72 as seen in forexample FIG. 2. An internal mounting frame 94 is disposed in chamber 14of liner 6 and seats on the inner surface of the base 10. While figureIII shows mounting frame 94 in an exploded view, the elements 91, 93, 95making up this member are fixed to each other by welding or any othersuitable means. Two threaded bolts 97 pass through openings 96 and 98 ofplate 90 and openings 100 and 102 of block C. Three nuts 104, 106 and108 are associated with each bolt 97 to firmly anchor block C to thefloor 2 of the filter.

FIGS. 16 AND 17

Another preferred anchoring assembly is shown in FIGS. 16 and 17. Thisanchoring system is similar to the assembly described above and,therefore, only the differences will be described in detail. Likeelements are given the same references numerals. In this assembly, nuts106 and internal mounting frame 94 have been omitted. A plurality ofinternal support members 110 (three of which are shown in FIG. 16) arepositioned in chamber 14. The support members 110 include two inclinedsidewalk 112 that mate with the sidewalk of liner 6 to provide internalsupport. The support members 110 each include leg 114 extending inwardlyfrom the corresponding sidewall 112. As seen in FIG. 17, a large gapexists between legs 114 to allow for the free flow of a washing fluidinto block C.

FIGS. 12 THROUGH 15

FIGS. 12 through 15 illustrate alternative means to connect theunderdrain block to a washing fluid supply where a flume is not used asthe washing fluid supply source. FIGS. 12 and 13 illustrate an end cap118 having an upper air opening 120 and a lower liquid 122 opening toallow the underdrain lateral B to be readily connected to an air pipeand a water pipe.

FIG. 14 illustrates an end cap 124 having a preformed air collar 126 anda preformed water collar 128 to assist in connecting both water and airsupplies to underdrain lateral B.

FIG. 15 illustrates an end cap 130 having a large water collar 132 tofacilitate connection of the underdrain lateral B to a water supply.

FIGS. 18 AND 19

FIGS. 18 and 19 disclose a preferred misalignment prevention collar 140that can be used with the preferred forms of the underdrains disclosedherein. Collar 140 includes a downwardly extending cylindrical sleeve142 that receives threaded bolt 97 and maintain the bolt in a verticalaxis preventing any misalignment of the bolt 97. Collar 140 furtherincludes a circular lip 144 disposed at the top of apex of outer liner40. Lip 144 engages top support plate 90 as the anchor assembly istightened to securely connect the underdrain laterals B to the floor 2of the filter. It should be noted that collar 140 can take manydifferent forms and can be positioned in other areas including thebottom of the underdrain blocks C.

FIGS. 20 THROUGH 42

Referring to FIGS. 23 and 24, a portion of filter F having a floor 200and four filter walls 202 (only two of which are shown) includes aplurality of underdrain laterals G formed in accordance with a preferredembodiment of the present invention. The filter media has been removedso that the underdrain laterals can be readily seen. It is to be notedthat FIGS. 23 and 24 depict one of numerous possible configurations ofthe present invention. It should be noted that the filter F can beformed from any suitable material including but not limited to concreteand stainless steel or other metal. Further, filter F can take any shapeas desired including but not limited to square, rectangular andcircular. The number of underdrain laterals G that are used in any givenunderdrain system will depend on the size of the filter.

Preferably, each of the underdrain laterals G are formed from aplurality of blocks H placed end to end with the joints between adjacentblocks H sealed by any suitable sealing method. However, underdrainlaterals G may be formed from one long underdrain block H. Theunderdrain blocks H, in the most preferred embodiment, are formed fromstainless steel. However, any suitable material may be used. Preferably,each of the underdrain blocks H are formed in a similar manner and,therefore, only one underdrain block H will be described in detail.

Referring to FIGS. 20 to 30 and 32 to 42, the preferred form ofunderdrain block H will now be described. The first of the two maincomponents of underdrain block H is an inner liner 206 seen in forexample FIGS. 20 to 22 and 25 to 28. Preferably, the inner liner 206 isformed from a single piece of stainless steel. Inner liner 206 isdepicted in blank form (i.e., prior to bending) in FIG. 25. Apex 208 ofliner 206 includes to vertically extending portions 205 and 207 that ateflush to each other. The apex 208 can be sealed in any known mannerincluding resistance welding. The base 210 of the liner 206 includes acentrally located opening 211 to receive washing liquid from flume I. Itshould be noted that only the underdrain blocks H disposed directlyabove flume need include central opening 211 as the washing liquid willenter the underdrain laterals G through openings 211 and travel in theinner liner 206 to the opposite end of the underdrain laterals G.

Referring to FIGS. 26 and 36, preferably a gas conduit 212 extendsthrough opening 213 so that the inner liner 206 can receive a washinggas including but not limited to air from a supply source. It should benoted that air could be supplied from flume I located below theunderdrain laterals G as shown in for example, FIG. 2. It should furtherbe noted that the present invention is not limited to use with filtershaving any type of flume, For example, the washing fluid, be it a liquid(e.g. water) or a gas (e.g., air) can be supplied through the ends ofthe underdrain laterals G as shown in FIGS. 12 through 15 and 34 to 36.

As is readily evident from the above discussion, chamber 214 formed byinner liner 206 simultaneously receives a liquid and a gas during abackwash or washing cycle that utilizes simultaneous liquid and gas. Itshould be noted, that the present invention is not limited to filtersystems employing a simultaneous liquid and gas washing procedure.Rather, the present invention can be used in filter systems employingany of the following washing procedures: (i) a separate liquid and gaswashing procedure; (ii) a liquid only washing procedure; (iii) a gasonly washing procedure; (iv) and a washing procedure that employssimultaneous liquid and gas for at least a portion of the washingprocedure/cycle.

A washing fluid mal-distribution member 216 is attached by fasteners(e.g. rivets) to each inclined sidewall 218 of liner 206 to preventmal-distribution of a washing fluid. Preferably, members 216 arepositioned below the gas/liquid interface formed in chamber 214 when asimultaneous liquid and gas washing procedure is employed and,therefore, the mal-distribution member will serve to preventmal-distribution of a washing liquid (e.g., water). However, the washingfluid can be a gas, For example, where only a washing gas is used duringat least a portion of the washing cycle then the mal-distribution memberwill serve to prevent mal-distribution of a washing gas (e.g., air), Inthe most preferred embodiment, each mal-distribution member 216 includesa pair of attachment feet or flanges 220 and 222 and outwardly extendingand angled walls 224 and 226. Preferably, mal-distribution member 216 isformed from a blank (see FIG. 29) of a single piece of stainless steel.Foot or flange 220 includes a plurality of openings 228 that align withopenings 230 of sidewalk 218 of inner liner 206 when mal-distributionmember 216 is mounted on each sidewall 218. Openings 228 and 230 receivea fastener (e.g., a rivet) to secure mal-distribution member 216 on thecorresponding sidewall 218. Similarly, foot or flange 222 includes aplurality of openings 232 that align with openings 234 of sidewalls 218of inner liner 206 when mal-distribution member 216 is mounted on eachside van 218. Openings 232 and 234 receive a fastener (e.g., a rivet) tosecure mal-distribution member 216 on the corresponding sidewall 218.

Referring to FIGS. 30 and 37, inclined and outwardly extending walls 224and 226 and the corresponding portion of sidewall 218 collectively forma chamber or sub-chamber 236. Openings 238 and 240 in liner 206 allow awashing fluid to pass from chamber 214 into chamber 236 during a washingcycle. Openings 242 in wall 224 and openings 244 in wall 226 allow awashing fluid to exit chamber 236 during a washing cycle. Preferably,the spacing between adjacent openings 242 is significantly greater thanthe spacing between openings 244. However, the number, shape and spacingbetween openings 242 may be varied as desired. Similarly the number,shape and spacing between openings 244 may be varied as desired.

Mal-distribution member 216 can take many forms including but notlimited to those illustrated in FIG. 31A through FIG. 31E. For example,mal-distribution member 216′ illustrated in FIG. 31A includes twovertically extending walls 246 in addition to the inclined walls 248.Mal-distribution member 216″ illustrated in FIG. 31B includes ahorizontally extending wall 250 in addition to the inclined walls 252.Mal-distribution member 216″′ illustrated in FIG. 31C includes fourinclined walls 254. Mal-distribution member 216″″ illustrated in FIG.31D includes two vertically extending walls 256 in addition to onehorizontally extending wall 258. Mal-distribution member 216″″′illustrated in FIG. 31E includes one arcuate wall 260 connected toflanges 220 and 222.

The second main component of blocks H is outer liner 270 as seen in forexample, FIGS. 32 to 37. Preferably, the outer line 270 is formed from asingle piece of stainless steel. Outer liner 270 is depicted in blankform (i.e., prior to bending) in FIG. 32. An opening 271 is formed inapex 272 of liner 270 so that conduit 212 can extend through the upperportion of liner 270. Referring to 21 and 22, base 274 of the liner 270includes an opening 276 aligned with opening 211 of inner liner 206 sothat a washing fluid from flume I can flow upwardly through opening 276and subsequently through opening 211 into chamber 214. It should benoted that only the underdrain blocks H disposed directly above flume Ineed include central opening 276. Referring to FIGS. 20 to 22 and FIG.32, base 274 is formed by wall portions 275 and 277. Wall portion 275may be connected in a sealed manner to wall portion 277 using anysuitable sealing technique including but not limited to resistancewelding.

As seen in FIGS. 36 and 37, outer liner 270 surrounds inner liner 206forming two outer chambers 280 and 282 on opposite sides of chamber 214.Chamber 280 can communicate but is not required to communicate withchamber 282 at the apex of the underdrain block H. However, as shown,chamber 280 does not communicate with chamber 282 at the apex as walls205 and 206 formed by apex 208 of inner liner 206 separates the twoouter chambers 280 and 282. However, openings can be readily formed inwalls 205 and 206 to permit communication between chamber 280 andchamber 282. Each of chambers 280 and 282 have an upper compartment 284formed above member 216 and a lower compartment 286 formed below member216. Each of the lower compartments 286 receives a washing liquid fromsub-chamber 236 through openings 242 during a washing procedureincluding a washing liquid. Each of the upper compartments 284 receivesa washing liquid from sub-chamber 236 through openings 244 during awashing procedure including a washing liquid.

Some of openings 290 are formed in sidewalk 296 of outer liner 270 belowmembers 216 to allow some liquid in lower compartments 286 to directlyenter the filter bed. Other of openings 290 are formed above members 216to allow washing fluids in upper compartments 284 to directly enter thefilter bed from the upper compartments 284. Openings may be formed inbase 274 of outer liner 270 below lower compartments 286 so that awashing fluid (e.g., water) exiting lower compartments through base 274can pass between base 274 and floor 200 of the filter so that anybacteria or other undesirable substance located adjacent or between thebase 274 and floor 200 can be flushed The filter bed may include one ormore layers of filter media supported by one or more layers of gravel.

When a washing liquid and washing gas are simultaneously used to wash afilter bed, a gas/liquid interface will typically be formed in chamber214 above members 216. Gas will enter chamber 214 through conduit 212.The gas will typically exit chamber 214 and enter upper compartments 284through the openings 300 and 302 formed in sidewalk 218 of inner liner206 above members 216. Openings 302 may be larger than openings 300. Itshould be noted that the size, spacing, number and configuration ofopenings 300 and 302 may be varied as desired.

A liquid/gas interface will in turn be formed in each of the uppercompartments 284. The washing gas will exit upper compartments 284 abovethe corresponding gas/liquid interface and pass into the filter bedthrough openings 290 formed in sidewalk 296 of outer liner 270 abovemembers 216. Referring to FIG. 37, members 216 may be spaced inwardlyfrom the inner surface of sidewalls 296 of outer liner 270. This willallow liquid from lower compartments 286 to travel upwardly into thecorresponding upper compartments 284.

Referring to FIGS. 20 to 24 a preferred form of support assembly L forsupporting and connecting inner liner 206 to outer liner 270 will now bedescribed. Support assembly L is configured to prevent relative movementbetween the inner liner 206 and the outer liner 270. Support assembly Lpreferably includes a substantially U-shaped base plate 320 includingbase 322 and two vertically extending walls 324 and 326 extendingupwardly from opposite sides of base 322. Outer liner 270 is supporteddirectly on base plate 320 between walls 324 and 326. Support assembly Lfurther includes inner liner plate 328 which is disposed in inner liner206 such that opening 330 of plate 328 is aligned with opening 211 ofinner liner 206. Plate 320 includes an opening 332 that is aligned withopenings 330 and 211 to allow a washing liquid to flow from flume I tochamber 214 of inner liner 206. A plurality of vertically extendingfasteners 334 pass through a plurality of openings 336 (eight openingsare shown) surrounding each of openings 332, 276, 211, 330 to securelyconnect inner liner 206 and outer liner 270 to the support assembly L insuch a manner that inner liner 206 cannot move relative to outer liner270. Fasteners 334 as illustrated include a bolt, a nut and a pluralityof washers. It will be readily appreciated that any suitable fastenermay be used. Referring to FIGS. 23 and 24, support assemblies L ofadjacent underdrain laterals G are connected to each other byhorizontally extending fasteners 340 passing through abutting verticallyextending walls of adjacent plates 320. Anchors 342 are positioned onunderdrain blocks H at spaced intervals along the length of theunderdrain laterals G to anchor underdrain laterals G to filter floor200. Bolts or all threads 344 connect the anchors 342 to floor 200.

Referring to FIGS. 38 to 41, a fluid pressure tap member M will now bedescribed. Fluid pressure tap member M includes a body 350 having aplurality of attachment feet or flanges 352 for securing member M to theinner liner 206 as shown in FIG. 38. Rivets or other fasteners passthrough openings 354 in flanges 352 to connect body 350 to inner liner206. Tapered portion 356 of sidewalls 358 of body 350 mates withinclined wall 226 of member 216. A pressure tap 360 extends outwardlyfrom body 350 and passes through a corresponding opening (not shown) inouter liner 270 so that a conduit extending from a pressure monitor canbe readily connected to the pressure tap 360. A sealant may be appliedaround the periphery of body 350 to create a sealed monitoring chamberbetween body 350 and the inner liner 206. A washing fluid enters thesealed chamber formed in part by body 350 from sub-chamber 236 throughopenings 244 in mal-distribution member 216. The washing fluid is thendirected to the pressure monitor through the conduit (not shown)connected to tap 360 to ascertain the pressure of the washing fluid.Preferably, a plurality of fluid pressure tap members M are uniformlyspaced (e.g., every eight feet) along the underdrain laterals G. Bymonitoring the pressure of the washing fluid along the length of theunderdrain laterals it is possible to determine if mal-distribution ofthe washing fluid is occurring and/or where such mal-distribution isoccurring. Where simultaneous liquid and gas is used in the washingcycle and the gas/liquid interface is located above member 216 then thepressure of the washing liquid will be monitored by member M and theassociated pressure monitor. Where only gas is used during a washingcycle, then gas pressure will be monitored by member M and theassociated pressure monitor.

Referring to FIG. 42, a pair of pressure tap members 380 and 382 areillustrated that may be used in place of and/or with member M.Alternatively, members 380 and 382 may be used prior to the underdrainlateral being installed in a filter housing. Members 380 and 382 areconfigured to be inserted into or over the end of inner liner 206 andouter liner 270, respectively. Tap 384 extends through both members 380and 382 so that a washing fluid can pass from the inner liner 206 topressure monitor connected to tap 384. Tap 386 extends through onlymember 382 so that a washing fluid can pass from the corresponding outerchamber formed between inner liner 206 and outer liner 270.

While this invention has been described as having a preferred design, itis understood that the preferred design can be further modified oradapted following in general the principles of the invention andincluding but not limited to such departures from the present inventionas come within the known or customary practice in the art to which theinvention pertains. The claims are not limited to the preferredembodiment and have been written to preclude such a narrow constructionusing the principles of claim differentiation.

We claim:
 1. An apparatus for se in a filter system for filtering wateror wastewater, said apparatus comprising: (a) at least one underdrainlateral block, said at least one underdrain lateral block having a firstouter sidewall, a second outer sidewall and at least one inner wallforming at least an r chamber, a first outer chamber and a second outerchamber, said first outer chamber and said second outer chamber being influid communication with said inner chamber; and, (b) a firstmal-distribution member being disposed in said first outer chamber forventing mal-distribution of a washing fluid, a second mal-distributionmember being disposed in said second outer chamber for preventingmal-distribution of a washing fluid, said first outer chamber and saidsecond outer chamber each having a first space for receiving a washingfluid, said first outer sidewall having at least one opening adjacentsaid first space of said first outer chamber through which a washingliquid in said first pace of said first outer chamber can exit said atleast one underdrain lateral through said first outer sidewall and saidsecond outer sidewall having at least one opening adjacent said firstspace of said second outer chamber through which a washing fluid in saidfirst space of said second outer chamber can exit said at least oneunderdrain lateral through said second outer sidewall wherein said firstspace of said first outer chamber is disposed above or below said firstmal-distribution member and said first space of said second outerchamber is disposed above or below said second mal-distribution member.2. The apparatus as set forth in claim 1, wherein: (a) said first spaceof said first outer chamber is disposed above said firstmal-distribution member; and, (b) said first space of said second outerchamber is disposed above said second mal-distribution member.
 3. Theapparatus as set forth in claim 1, wherein: (a) said firstmal-distribution member is a separate piece attached to a wall of saidfirst outer chamber; and, (b) said second mal-distribution member is aseparate piece attached to a wall of said second outer chamber.
 4. Theapparatus as set forth in claim 1, wherein: (a) said first space of saidfirst outer chamber is disposed below said first mal-distributionmember; and, (b) said first space of said second outer chamber isdisposed below said second mal-distribution member.
 5. The apparatus asset forth in claim 1, further including: (a) a fluid pressure tap tember operably associated with a fluid discharge opening formed in saidunderdrain block, said fluid pressure tap member including a tap that atleast one component of a pressure monitor can be connected to so thatpressure of a fluid passing through the fluid discharge opening can bemonitored.
 6. The apparatus as set forth in claim 5, wherein: (a) saidfluid discharge opening is formed in said at least one inner wall.
 7. Anapparatus for use in a filter system for filtering water or wastewater,said apparatus comprising: (a) an underdrain lateral block, saidunderdrain lateral block having a first outer side all, a second outerside all and at least one inner wall forming at least one primarychamber, at least one lower secondary chamber, at least one intermediatesecondary chamber and at least one upper secondary chamber, saidintermediate secondary chamber being disposed between said at least onelower secondary chamber and said at least one upper secondary chamber,said primary chamber being in fluid communication with said at least oneintermediate secondary chamber, said at least one intermediate secondarychamber being in fluid communication with said at least one lowersecondary chamber and said at least one upper secondary chamber suchthat said at least one intermediate secondary chamber directs a washingfluid to said at least one lower secondary chamber and said at least oneupper secondary chamber wherein said primary chamber receives a washingfluid prior to said at least one lower secondary chamber, said at leastone intermediate secondary chamber and said at least one upper secondarychamber.
 8. An apparatus as set forth in claim 7, wherein: (a) said atleast one lower secondary chamber has at least one opening for releasinga washing fluid into a filter bed from said at least one lower secondarychamber.
 9. An apparatus as set forth in claim 7, wherein: (a) saidprimary chamber is formed by a first piece of material and saidintermediate secondary chamber is formed by said first piece of materialand a second piece of material.
 10. An apparatus as set forth in claim9, wherein: (a) said first piece of material and said second piece ofmaterial are formed from stainless steel.
 11. An apparatus for use in afilter system for filtering water or wastewater, said apparatuscomprising: (a) at least one underdrain lateral block, said at least oneunderdrain lateral block having an inner liner and an outer linerforming an inner chamber, a first outer chamber and a second outerchamber, said first outer chamber and said second outer chamber being influid communication with said inner chamber, said outer linersurrounding at least a portion of said inner liner; and, (b) a supportassembly for preventing relative movement between said inner liner andsaid outer liner when a washing fluid is directed through the at leastone underdrain block, said support assembly including a first memberengaging a portion of said inner liner and a second member engaging aportion of said outer liner.
 12. The apparatus as set forth in claim 11,wherein: (a) said first member is disposed in said inner chamber. 13.The apparatus as set forth in claim 12, wherein: (a) said first memberis a plate having an opening through which a washing fluid passes duringa washing cycle.
 14. The apparatus as set forth in claim 13, wherein:(a) said second member includes a base and two vertical walls extendingfrom opposite sides of said base, said outer liner being disposedbetween said two vertical walls of said second member; and, (b) saidbase having an opening through which a washing fluid passes during awashing cycle.
 15. The apparatus as set forth in claim 14, wherein: (a)said support assembly further includes a plurality of fastenersextending through a portion of each of said two vertical walls, saidplurality of fasteners connect said support assembly to supportassemblies of underdrain blocks on each side of said at least oneunderdrain block.
 16. An apparatus for use in a filter system forfiltering water or wastewater, said apparatus comprising: (a) at leastone underdrain lateral, said at least one underdrain lateral includingat least one outer wall and at least one inner wall forming at least afirst chamber and a second chamber, said first chamber being in fluidcommunication with said second chamber; (b) a sub-chamber for receivingand directing a washing fluid, said sub-chamber being formed in saidfirst chamber; and, (c) a first mal-distribution member being disposedin said first chamber for preventing mal-distribution of a washingfluid, said first mal-distribution member and at least a portion of saidat least one inner wall forming at least a portion of said sub-chamberwherein said mal-distribution member is a separate piece from said atleast one inner wall.
 17. An apparatus as set forth in claim 16,wherein: (a) said first chamber is a secondary chamber receiving awashing fluid from said second. chamber during a washing cycle, saidsecond chamber being a primary chamber; and, (b) said firstfinal-distribution member includes two substantially planar attachmentfeet connected by a raised portion wherein said raised portion extendsoutwardly from said primary chamber.
 18. An apparatus as set forth inclaim 16, wherein: (a) said first mal-distribution member is spaced fromsaid at least one outer wall.
 19. An apparatus as set forth in claim 16,wherein: (a) said first mal-distribution member is disposed below aliquid/air interface formed in said primary chamber when both liquid andair are used simultaneously during a washing cycle.
 20. An apparatus foruse in a filter system for filtering water or wastewater, said apparatuscomprising: (a) at least one underdrain lateral, said at least oneunderdrain lateral including at least one outer wall and at least oneinner wall forming at least a primary chamber and a secondary chamber,said primary chamber being in fluid communication with said secondarychamber such that said primary chamber directs a washing fluid during awashing cycle into said secondary chamber; and, (b) a fluid pressure tapmember being connected to said at least one underdrain lateral such thatsaid fluid pressure tap member is operably associated with a fluiddischarge opening formed in said at least one underdrain lateral, saidfluid pressure tap member including a tap configured so that at leastone component of a pressure monitor can be connected to said tap so thatpressure of a fluid passing through the fluid discharge opening can bemonitored.
 21. An apparatus as set forth in claim 20, wherein: (a) saidfluid pressure tap member is connected to said at least one inner walland said tap extends through at least a portion of said secondarychamber.